Staggered needle cut-pile tufting machine

ABSTRACT

A staggered needle cut-pile tufting machine in which the loopers cooperating with one row of needles are longer than the loopers cooperating with the other row of needles so that each looper may seize a loop from its associated needle. The loopers are constructed and positioned in the looper bar with the throats of all the loopers aligned. The loop cutting knives are mounted in a single oscillating knife block and are aligned to cut substantially at the throat of a respective cooperating looper. The effect is that neither loop seizure nor loop cutting are compromised. Also disclosed is a needle bar capable of shifting laterally with respect to the loopers.

[ Oct. 21, 1975 United States Patent [191 Crumbliss et a1.

3,402,686 9/1968 Rodstein et 112/79 R 3,440,983 4/1969Woodcock........................ 112/79 R 3,492,956 2/1970 112/79 RSTAGGERED NEEDLE CUT-PILE TUFTING MACHINE [75] Inventors: Robert T.Crumbliss; Jerry V.

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[56] References Cited and are aligned to cut substantially at the throatof a UNITED STATES PATENTS respective cooperating looper. The effect isthat neither loop seizure nor loop cutting are compromised. Alsodisclosed is a needle bar capable of shiftin ally with respect to theloopers.

g later- Card 112/79 R Dedmon............................ Card 7 Claims,6 Drawing Figures U.S. Patent Oct. 21, 1975 SheetlofZ 3,913,505

US. Patent Oct. 21, 1975 Sheet20f2 3,913,505

STAGGERED NEEDLE CUT-PILE TUFTING MACHINE BACKGROUND OF THE INVENTIONThe present invention relates to tufting machines, and more particularlyto an improved apparatus and method for manufacturing cut-pile fabric ona tufting machine having laterally spaced parallel rows of needles.

It is known to create a dense loop pile fabric by a tufting machinehaving parallel rows of needles laterally spaced to provide a smallergauge (US. Pat. of Webb No. 3,492,956). However, cut-pile tufted fabric,which is today of greater popularity, has not been produced withcomparable density as to the loop pile fabric. One reason for this isthe space problem created by the many gauge parts. In cut-pile tuftingmachines each needle includes an associated looper for seizing a loopand an associated knife for cutting the seized loops. When parallel rowsof staggered needles are applied in a tufting machine the loopers havebeen either spaced in separate looper bars, spaced differently in onesupporting looper bar as illustrated in the aforesaid Webb Patent, orare of different sizes as illustrated in US. Patent of Woodcock, No.3,440,983. In a cut-pile tufting machine the loops are fed onto thelooper bills and the knives cut when the loop is at the throat at therear of the bill after there are a number of seized loops positioned onthe bill. Experience has taught that this cutting relationship should bemaintained between all the loopers and knives. When manufacturingcut-pile fabrics, it would be necessary to have knives of differentlengths or knives mounted on different oscillating knife blocks if theloopers are mounted in space separate looper bars or are spaceddifferently in a single row looper bar. This for obvious reasons is notdesirable. In the aforesaid Woodcock Patent in order to have the knivescut at the looper throats of the different size SUMMARY OF THE INVENTIONTo overcome the limitations of the prior art the present inventionprovides apparatus for producing a dense cut-pile fabric on a tuftingmachine having first and second laterally spaced parallel rows ofneedles. The loopers associated with the first row have a loop-seizingbill portion longer than that of the loopers associated with the secondrow by substantially the spacing between the first and second rows, andall the loopers are positioned in a supporting looper bar with thethroats of the loopers substantially aligned laterally. The knivesassociated with the loopers are positioned in a supporting knife barwith all the knives laterally aligned so as to cut the loops at thethroat of the associated looper.

Another feature of the invention provides the loop seizing portion ofthe bill of the longer bill loopers with a slight angular undercutrelative to the shorter bill loopers.

Another feature of the invention is the inclusion of a means forimparting relative lateral movement between the needles and the backingfabric in accordancewith a pattern to provide unique cut-pile patterneffects wherein none of the yarn is hidden, and therefore wasted, as itis when using loop or loop/cut machines with a yarn feed patternattachment.

It is therefore the primary object of this invention to provide acut-pile tufting maching having first and second laterally spacedparallel rows of needles which can provide unique tufted fabric.

BRIEF DESCRIPTION OF THE DRAWINGS The particular features and advantagesof the invention as well as other objects will become apparent from thefollowing description taken in connection with the accompanyingdrawings, in which:

FIG. 1 is a fragmentary sectional view of a tufting machine embodyingthe present invention;

FIG. 2 is a partial perspective view of the loop form ing and cuttingmachanism of the present invention;

FIG. 3 is a side view of the mechanism illustrated in FIG. 2;

FIG. 4 is a cross sectional view taken substantially along line 4--4 ofFIG. 3;

FIG. 5 is a side elevational view of the loop forming and severingmechanism of FIG. 1 at an instant during the operating cycle; and

FIG. 6 is a diagrammatic view of a typical patterned cut-pile fabricproduced by the tufting machine illustrated in FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to theaccompanying drawings, there is illustrated a portion of a tuftingmachine comprising a frame 10 including a head 12 over-hanging a bed 14.A backing fabric F in the form of a web is passed from front to rearacross a bed plate 16 in the direction of the arrow A in FIG. 1 by aconventional feed mechanism including feed rolls l8 and 20. Mounted inthe head 12 for endwise reciprocation is a push rod 22 which at itslower end carries a needle bar 24 that in turn carries two parallel rowsof needles 26 and 28. The needles in the rear row 28 are spaced from theneedle in the front row 26 and are staggered relatively to the front rowas best illustrated in FIG. 2. The stagger is such that needles in therear row are off-set substantially mid-way between the needles in thefront row. Thus, the gauge of the machine is substantially half thedistance between adjacent needles in each row. Both rows of needles inthe preferred embodiment are mounted in a common needle bar 24 which isslidable in a channel formed in a needle bar carrier 30 so that theneedle bar 24 can be shifted laterally in a manner disclosed in US. Pat.of Bryant, No. 3,026,830. As illustrated in this patent the timing andamount of the shifting is controlled by a pattern mechanism such as acam. It should be understood that the needles 26 and 28 may be mountedin separate needle bars which may be slidably positioned individually orseparately as known in the art. The rod 22 is adapted to be reciprocatedby conventional mechanism (not shown) including a crank rod thatcooperates with an eccentric upon a main shaft journalled longitudinallyof the head. In operation, the needles are, of course, threaded withyarn Y feed by conventional means.

Longitudinally of the bed 14 there is journalled a hook or looper shaft32 on which is mounted a bracket 34 carrying a looper bar 36 having aplurality of parallel spaced slots 38 adapted to receive loopers 40 and42. In order to form the loops or tufts during successive penetrationsof the needles, there is provided a looper for each needle for holdingthe loop or tuft during the upward stroke-of the needles. Thus, eachneedle 26 has an associated looper 40 and teach needle 28 has anassociated looper 42 for seizing'a loop deposited by the associatedneedle. The looper shaft 32 is oscillated in a conventional mannerthrough means driven off the main shaft. Each looper 40 and 42 includesa body portion44 including a blade 46, and a shank 48 adapted to bereceived within the slots 38. Each looper 42 further includes a looppenetrating bill 50 angularly extending from the body portion, and eachlooper 40 includes a bill 52 angularly extending from its body portion.Between the blade 46 of each body portion and the respective bill 50 and52 is what shall be defined as the looper throat 54. In accordance withthe present invention, the throats, v54 of all the loopers 40 and 42 aresubstantially aligned laterally as best illustrated in the elevationalview of FIG. 3. Thus, the bill portions 52 of the loopers 40 are longerthan the bills of the loopers 42 to compensate for the spacing betweenthe needles 26 and 28 in the direction of feed.

In order to form cut-pile each looper has an associatedknife 56 carriedby a knife bar 58 mounted on a shaft 60 which is conventionallyoscillated through mechanism driven off the main shaft in timed relationto the oscillation of the loopers. Each knife 56 includes a cutting edge62 which, as best illlustrated in FIG. 4, is biased by the flexibilityof the knives against the side of the looper and is adapted to cooperatewith the bottom edge of each looper bill which acts as a ledger to severthe loops on the blade to form cut-pile. In accordance with the presentinvention each knife associated with the looper 42 is aligned with eachknife associated with the loopers 40. For optimum cutting the knivesoperate at the rear portion of the bills, and preferably at the throat,so that several loops may be present on the bill. The loops are severedby the knives as they move back on the bill as the fabric F is fed andthus carries the loops into the area where the knife is operative. Sincein accordance with the present invention the throats of all the loopersare aligned, and the knives are aligned, each knife will cut at thethroat of its associated looper.

In the operation of the above mechanism the needles 26 and 28 arereciprocated to penetrate the fabric F and to project the loops of yarnthere through. As the needle rises to cast a loop, the loopers areadvanced in its loop penetrating stroke wherein the bills 50 and 52enter respective loops of yarn presented by the needle. The loops remainon the hook and as the fabric is advanced, they are carried back on thebill and are eventually severed by the knives 56 at the throats 54. FIG.best illustrates this operation wherein there is shown loops 64 formedby the interaction of the needles 26 with the loopers 40 and loops 65formed by the interaction of the needles 28 and the loopers 42. Each ofthese loops are carried back on the respective bills 50 and 52 tom edgeof the bills 52 of the longer bill loopers 40 may be at an angle ofapproximately 5 to 7 degrees to the equivalent loop seizing portion ofthe shorter bill loopers.

During the operation of a machine incorporating the present invention,it has been found that unique and v desirable cut-pile patterns areobtainedwhen relative and are severed atvthethroat 54 by the knives 56to produce cut-pile 66.

It has been found that because of the properties of certain yarns,notably the polyesters, the loops 64 formed on the loopers 40 tend topile up and slip off the longer bills 52 when the underside of the bills52 are substantially parallel to the needle plate 16 during looppenetration. It has been found that if the underside of the bills 52 areunder-cut by an angle (1) of approximately 5 to 7"degrees this problemis alleviated. Thus, 7

when properly positioned in the looper bar 36 the botlateral shiftingmovement between the needles and the backing fabric are provided. Suchrelative movement may be provided by a sliding needle bar arrangement asillustrated in the aforesaid Bryant U.S. Pat. No. 3,026,830 or it may beprovided by a shifting needle plate as disclosed in U.S. Pat. of Card,No. 3,301,205. This pattening effect is especially interesting whendifferent color yarn is selectively threaded into the needles of theparallel rows. For example, FIG. 6 illustrates a typical patternedcut-pile fabric manufactured by the machine illustrated in FIG. 1 and inwhich a yarn ,of a

first color 68 is threaded in a three to one relationship to a yarn of asecond color 70, and relative lateral movement between the needles andthe backing fabric isimparted by an amount corresponding to the spacingbetween the needles in one row every other penetration of the needles.It should be understood that the lateral shifting movement must occurwith the present invention by an amount comprising multiples of thespacing between needles in each row, because the loopers 40 mustcorrespond with the needles 26 and the loopers 42 must correspond withthe needles 28. Pattening of cut-pile fabric accomplished in this mannerrather than by the use of a yarn feed roll attachment, as is generallyused with loop pile and loop/cut-pile leaves every yarn visible. This isnot the case with loop pile or loop/cutpile in which some yarn isinserted which is hidden as short loops in the pattern. Thus no yarn islost in the pattern as it is with loop and loop/cut-pile.

Numerous alterations of the structure herein disclosed will suggestthemselves to those skilled in the art. However, it is to be understoodthat the present disclosure relates to a preferred embodiment of theinvention which is for purposes of illustration only and not to beconstrued as a limitation of the invention. All such modifications whichdo not depart from the spirit of the invention are intended to beincluded within the scope of the appended claims.

Having thus described the nature of the invention, what is claimedherein is:

1. In a tufting machine for making cut-pile fabric, means for supportinga backing fabric fed from front to rear of the machine, a needle barmeans carrying front and rear laterally extending spaced rows of yarncarrying needles disposed on one side of the backing fabric, the needlesin the rear row being staggered relatively to the front row, means forreciprocating the needles to penetrate and insert loops of yarn throughthe backing fabric, a looper associated with each needle disposed on theopposite side of the backing fabric from said needles, each looperincluding a body portion and a loop penetrating bill angularly extendingfrom said body portion and defining a throat therebetween, the bills ofthe loopers associated with the front row of neerow, means forsupporting the body portion of said loopers with all the throatssubstantially aligned later- I ally, means for actuating said loopers sothat said bills enter respective loops of yarn presented by said needlesto seize and hold the loops when the needles are withdrawn, a knifedisposed on one side of each hook and having a cutting edge forcooperating with the respective blade adjacent the throat for severingloops thereon to form cut-pile, means for supporting said knivessubstantially aligned laterally, and means for actuating said knives intimed relation to the actuation of said loopers for movement in a pathwherein said cutting edges are moved into cutting engagement with therespective blade.

2. In a tufting machine as recited in claim 1 wherein the loop seizingportion of the bills of the longer bill loopers are at an angle to theloop seizing portion of the shorter bill loopers.

3. In a tufting machine as recited in claim 2 wherein said angle isapproximately 5 to 7 4. In a tufting machine as recited in claim 1including means for imparting relative lateral movement between saidneedles and said backing fabric in accordance with a pattern.

5. A looper assembly for a tufting machine comprising a looper bar, aplurality of loopers, each looper including a body portion and a looppenetrating and seizing bill angularly extending from said body portionand defining a throat there between, means for mounting said bodyportions in said looper bar in a row with all the throats substantiallyaligned, and the bills on alternate loopers being longer than the billsof the adjacent loopers.

6. A looper assembly as recited in claim 5 wherein the loop seizingportion of the bill of the longer bill loopers are at an angle to theloop seizing portion of the shorter bill loopers.

7. A looper assembly as recited in claim 6 wherein said angle isapproximately 5 to 7

1. In a tufting machine for making cut-pile fabric, means for supportinga backing fabric fed from front to rear of the machine, a needle barmeans carrying front and rear laterally extending spaced rows of yarncarrying needles disposed on one side of the backing fabric, the needlesin the rear row being staggered relatively to the front row, means forreciprocating the needles to penetrate and insert loops of yarn throughthe backing fabric, a looper associated with each needle disposed on theopposite side of the backing fabric from said needles, each looperincluding a body portion and a loop penetrating bill angularly extendingfrom said body portion and defining a throat therebetween, the bills ofthe loopers associated with the front row of needles being longer thanthe bills of the other loopers by substantially the spacing between thefront and rear row, means for supporting the body portion of saidloopers with all the throats substantially aligned laterally, means foractuating said loopers so that said bills enter respective loops of yarnpresented by said needles to seize and hold the loops when the needlesare withdrawn, a knife disposed on one side of each hook and having acutting edge for cooperating with the respective blade adjacent thethroat for severing loops thereon to form cutpile, means for supportingsaid knives substantially aligned laterally, and means for actuatingsaid knives in timed relation to the actuation of said loopers formovement in a path wherein said cutting edges are moved into cuttingengagement with the respective blade.
 2. In a tufting machine as recitedin claim 1 wherein the loop seizing portion of the bills of the longerbill loopers are at an angle to the loop seizing portion of the shorterbill loopers.
 3. In a tufting machine as recited in claim 2 wherein saidangle is approximately 5* to 7*
 4. In a tufting machine as recited inclaim 1 including means for imparting relative Lateral movement betweensaid needles and said backing fabric in accordance with a pattern.
 5. Alooper assembly for a tufting machine comprising a looper bar, aplurality of loopers, each looper including a body portion and a looppenetrating and seizing bill angularly extending from said body portionand defining a throat there between, means for mounting said bodyportions in said looper bar in a row with all the throats substantiallyaligned, and the bills on alternate loopers being longer than the billsof the adjacent loopers.
 6. A looper assembly as recited in claim 5wherein the loop seizing portion of the bill of the longer bill loopersare at an angle to the loop seizing portion of the shorter bill loopers.7. A looper assembly as recited in claim 6 wherein said angle isapproximately 5* to 7*